Trim-panel manufacture and apparatus



' A. s. MITCHELL Er AL 2,170,562

TRIM-PANEL MANUFACTURE AND APPARATUS Aug; 22, 1939.

3 Sheets-Sheet l Aug. 22, 1939. A. s`. MITCHELL Er AL 2,170,652

TRIM-PANEL MANUFACTURE AND APPARATUS Filed June 2'7, 1936 l I 5 Sheets-Sheet 2 A. s. MITCHELL Er AL 2,170,662

TRIM-PANEL MANuFAcTuaE AND APPARATUS Filed June 27', 195e s sheets-sheet s j (t, v

Aug. 22, 1939.

W. W1. ,MANS W Patented Aug. '22, v1939 PATENT OFFICE TRIM-PANEL MANUFACTURE APPARATUS Allister S. Mitchell and Harold M. Ratley, lletroit, Mich., assignors to National Automotive Fibres, Inc., Detroit, Mich., a corporatlon of Delaware Application June 27, 1936, Serial No. 87,776

10 Claims.

This invention relates particularly to the manufacture of trim-panels for the interior trim of automobile bodies and to apparatus for facilitating the manufacture of such panels.

It is known to provide, for the purpose of up- 'holstering automobiles, trim-panels equipped with snap-fasteners which can be inserted through holes or sockets in the framework of the body of the automobile.

It is desirable that such upholstery panels shall be provided, between the foundation-plate portions cut away to conform vto the contour of the lower portion of the door, and may have openings, as for example for the handle-shaft, the shaft of the window-operating mechanism, or the like. Heretofore, it has been the practice to provide a relatively stiff sheet of material to serve as a foundation-plate, thisv sheet being cut to suitable contour and provided with necessary openings; and, where a layer of filling material has been interposed between the foundation-plate and the finish-fabric, itY has been common practice to employ a sheet of what is known in the trade as blue wedding, or other felted material, the padding being'cut or stamped by dies to give it a contour corresponding with the base-plate and to provide openings corresponding with those in the base-plate. In this method of manufacture, considerable diculty is encountered in applying the padding to the base-plate and getting it to register properly. Such method of manufacture involves undue expense, and, moreover, fails to give a desirably even surface next to the cover-fabric.

In the application of Allister S. Mitchell Ser. No. 63,968, filed February 14,1936, there is disclosed apparatus for producing bat-covered panelboards by a continuous method, such bat-covered panel-boards being suitable for the production of trim-panels by applying cover-fabrics to the A, same.

` The present invention utilizes the broad idea of trim-panels in a very economical manner.

In accordance with the present invention in a preferred embodiment, a strip of unwoven fibrous material is fabricated and fed upon a conveyor; pre-cut panel-boards, preferably equipped With socket-plates (for attaching fasteners) are sprayed on one surface with a suitable adhesive and laid upon the traveling strip of batting; the continuous batting strip carrying the panelboards passes through a suction-equipped brushtrimmer which operates to rupture the bat between panel-boards and effect trimming of the bat material about the edges of the panel-board; the bat-covered, trimmed panel-boards are then advanced by a'conveyor, (bat side up) and templets are placed in succession upon the bats, the templets being of lesser area than the bats; the advancing templet-co-vered panels then pass through a second suction-brush-trimmer, the suction being applied from above, and the edgeportions of the bats are, in succession, trimmed against the edges of the templets, thus giving the effect of a beveled edge to the bats. The bat-covered panel-boards are now ready to be covered with fabric. They are transferred to a conveyor upon which covers are placed in succession; Vthe panels are placed, bats down, upon the advancing covers; they pass through a spraying booth where the margins of the panel-boards and the margins of thecovers aresprayed with adhesive; they.then continue thro-ugh a drier to permit the adhesive to become suitably tacky; operators then fold the margins of the cover over the margins of the panel-board and elect the pasting operation; the panels then are car- Y ried past another operator Who, by means of an electrical implement, cuts holes in the pasted margins of the coverregistering with the holes in the metal clips which underlie the margins of the cover. Finally, the trim-panels preferably are passed through a gang sewing machine which produces lines of stitching which extend through the panel-board, bat, and cover-fabric.

The invention is illustrated in a preferred embodiment in the accompanying drawings, in which-Y Fig. 1 is a diagrammatic view, in plan, of apparatus for enabling the process described to bev practiced economically; Fig. 2, a broken side elevational View illustrating the manner in which the continuous bat, carrying a succession of panel-boards, is passed through the first suction-trimmer; Fig. 3, a broken side elevational View which may be understood to be a continuation at the left-hand end of Fig. 2, showing the second suction and brush trimmer employed, the left-hand end of Fig. 3 illustrating bending rolls which may be employed, optionally; Fig. 4, a broken longitudinal sectional view on a larger Scale showing the first combination suction and brush-trimmer employed, the second one being similar; Fig. 5, a broken sectional view showing in detail the bending rolls which appear at the left-hand end of Fig. 3; Fig. 6, a cross-sectional View of a trim-panel after it has been completed and Fig. '7, a sectional View taken as indicated at line 'l of Fig. 6.

In the illustration given, A designated batfabricating mechanism adapted to fabricate and deliver a continuous bat A upon a conveyor A2; B, brush-trimming mechanism., preferably equipped with a surmounting suction device B and operating to rupture the bat between panel-boards and effect trimming of the bats at the edges of the panel-boards; C, a conveyor which serves -to feed the continuous bat A and panel-boards carried thereby to the mechanism B; D, a conveyor which receives the bat-covered panel-boards from the mechanism B; E, bat-trimming mechanism preferably surmounted by a suction-device E', the conveyor D serving to deliver bat-covered panel-boards and surmounting templets to the mechanism E, where the edge-portions of the bats are trimmed about the edges of the templets, in succession, thus giving a chamfered effect to the edges of the bats; F, a conveyor which receives the bat-covered panel boards from the mechanism E'; G, a set of bending rolls which may Vbe employed optionally to render the panels slightly concavo-convex, this expedient being desirable when it is desired to effect particularly tight stretching of the cover-fabric by straightening the panel; H, a return conveyor for returning the templets; I, a table or support upon which the bat-covered panel-boards may be stacked; J, a table upon which is placed a supply of covers K; L, a conveyor which leads through a spraying booth M; N, a drier through which the sprayed panels pass to permit the adhesive to acquire suitable tackiness; O, a conveyor serving to carry the panels through the drier; and P, a gang sewing machine which may be employed to stitch the covers to the panel-boards.

Referring to Fig. l, the bat-fabricating mechanism preferably comprises two or. more Garnett machines which operate, in a well-known manner, to lay films of cotton on, the moving conveyor A2. In the illustration given, the delivery apron of the so-called camel back of a Garnett machine is designated l, but,as intimated, any desired number of machines may be employed to build up the desired thickness of batting on the conveyor A2. The conveyor A2 and the conveyors C, D and F preferably are geared to operate at about the same speed. Preferably, they are all geared to operate in synchronism with the Garnett machine.

The continuous bat A', as formed, may be passed through compression rolls, indicated at 2, and thence to the conveyor C. Panel-boards, designated Q, are sprayed on one surface in a booth R. They are then placed upon the traveling continuous bat A with the adhesive against the bat, and are carried with the bat through the bat-rupturing and trimming mechanism B. The panel-boards are suitably spaced upon the continuous bat, as appears at the lower right-hand portion of Fig. 1.

The continuous bat A' and the adhering panelboards Q, in entering the mechanism B, pass between the compression rolls 3 (Figs. 2 and 4) which serve also as feed-rolls. The mechanism B is equipped also with a lower brush-type feed roll d and an vupper coacting brush-,trimmer 5; also with a lower brush-type feed-roll 6 and a coacting upper brush-trimmer l; also with a nal pair of feed-rolls 8 from which the panels are delivered to the conveyor D.

The individual bats, after severance and trimming, areV designated A3.

The drive mechanism which operates the conveyors and the feed-rolls of the mechanisms B and E at a corresponding uniform speed is designated S. The brush-trimmers 5 and 1 are operated at a very high rate of speed. Preferably, they are operated by electric motors T through the medium of the belt T', as shown in Fig. 4.

The trimmer 5 rotates in the direction indicated l by the arrow, that is, clockwise as viewed in Fig. 4. It is equipped with wire bristles 52L which incline Vina direction opposite the direction of rotation of the brush. The brush-trimmer 1 rotates counterclockwise as viewed in Fig. 4 and is equipped with wire bristles la which incline away from the direction of rotation. A suction-box U is disposed over the brush trimmer and equipped with a conduit U through which suction may be applied. It will be noted that the feed rolls form an open bed through which the continuous bat A and the surmounting panel-boards travel. In passing through the suction-trimmer, the material of the continuous bat is ruptured between the spaced panel-boards, and the marginal portion of Ithe bat is drawn upwardly about the edges of the panel-board and brought within the `trimming action of the rapidly rotating brush-trimmers 5 and T. The brush l operates against the forwardly presen-ted edges of the panel-boards. If the panel-'boards have openings therethrough, the cotton is drawn through and ruptured at said openings and is trimmed. The brush 'la operates against the forwardly presented edges of the openings. The brush 5 operates against the rearwardly presented edges of the panel-boards. The brush-trimmers are of sufcient length to extend past the lateral edges of the panel-boards, and the material of the bat is drawn upwardly about the lateral edges of the panel-boards and subjected to the action of the trimmers.

The operation of the mechanism B leaves a fullness: of cotton at the edges of the panelboards. It is desirable to reduce the fullness of the cotton at the edges and produce a chamfered effect. This may be done by employing templets and passing the panels through the brush-trimmer E, which corresponds in construction and operation with the brush-trimmer B.

Referring to the left-hand portion of Fig. 2, it will be noted that the panel-boards are uppermost. However, after the panel emerges from the mechanism B, an operator reverses the panel on the conveyor D, soV that the bat-covered side will be uppermost as the panel-board approaches the Ymechanism E. Another operator at the opposite side of the conveyor D takes a templet from4 the conveyor H (Fig. l) and extends it over the conveyor D. The two operators together place the templet, designated V, over the bat-covered panel-board, as shown in Figs. l and 3. The templet is of lesser area than the panel. That is, it is laid so that its edges are not quite flush with the edges of the panel. In some cases, it is desired to remove the cotton at what will be the lower margin of the trim-panel to make room for an especially strong covering at the lower margin of the trim-panel where scuiiing is apt to occur near the floor of the machine. In such case, the templet may be shortened suiiciently to permit the cotton to be removed to any desired extent.

The conveyor D carries the bat-covered panel and the surmounting templet through they mechanism E. As stated, the mechanism E is similar in construction and operation to the mechanism B which is shown in detail in Fig. 4. However, in this instance the brush trimmers 5 and 'I of the mechanism E serve to trim the edge-portions of the bat against the edges of the templet V.

The templet may comprise a thin sheet-metall member corresponding in general contourfto the contour of the panel-board, but of lesser area. The brush-trimmers 5 and 'l of the mechanism E work against the upper surface of the thin templet and over the edges of the templet, neatly trimming away cotton projecting past the templet. This produces a taper at the edges of the bat, as indicated at 9 in Fig. 3. It will be understood that when the material emerges from the mechanism E, the templet surmounts the bat A3. The templet is removed by an attendant and placed upon the return conveyor I-I. If it be not desired to bend the panels in the manner illustrated in Fig. 3, the attendant may remove the panels before they pass into the bending rolls G; otherwise, the panels may be alowed to pass through the rolls and may then be placed upon the table I. They may be carried in stacks to the front end of the conveyor L; or, Vif desired, a return conveyor may be employed. In this connection it is to be understood that Fig. l is more or less diagrammatic and that the apparatus shown at the upper portion of Fig. 1 may -extend rearwardly from about the vicinity of the table I, if desired.

In the Mitchell application mentioned above, the suction is applied to the bat-rupturing and trimming mechanism at a point below the path of travel of the continuous bat. In that case, the panel-boards are disposed beneath the plane of the continuous bat. So far as the operation of rupturing the continuous bat and eiecting first trimming is concerned, it is possible to have the suction-device located either above or below the path of travel of the continuous bat and the adhering panel-boards. placed below, the panel-boards unde-rlie the continuous bat; if the suction-device be placed above, the panel-boards overlie the continuous bat. With respect to the mechanism E, shown in Fig. 3, however, it is particularly Vdesirable that the suction-device be located above the path of travel of the panels. In such case, the bat-side o-f the panel is up. This enables the templets to be applied readily and correctly. Experience has demonstrated that the trimming can be properly effected and the cotton which is torn away at the edges of the bat by a kind of an abrading action eected by the rotating bristle-equipped brushes, will be satisfactorily removed from the apparatus by means of the up-draft suction. In a similar manner, the apparatus shown in Figs. Zand 4 will operate to draw the bat upwardly about the edges of the panel-board, effect rupturing of the bat, cause the individual bats to be trimmed, in succession, about the edges of the panel-boards, and carry the trimmed-away cotton off through the conduit U. The trimmed cotton may be returned by suitable conveyors (not shown) to the Garnett machines to be used afresh in forming the continuous bat.

If the suction be,

As shown in Fig. 1, pre-cut covers K of suitable dimensions are placed upon the conveyor L. Batcovered panel-boards, the bats being suitably trimmed and chamfered, are placed upon the covers with the bats adjacent the covers. The conveyor L carries the assemblies in succession through the spraying booth M, where an attendant sprays the margins of the panel-boards and the projecting margins of the covers. The assembly is then passed through the drier N, where the adhesive acquires a desirable tackiness. Operators stationed along the conveyor O effect the folding of the margins of the covers and the pasting of said margins against the surfaces of the panel-boards. Near the left-hand portion of Fig. 1 the pasted margin is designated I. In this operation, preferably the margin is of sucient width to more than cover the metal socket plates designated Il which are applied to the panelboards before the covering operation begins. The socket-plates ll ordinarily are in the form of small sheet metal plate-s having openings therethrough and having brads which are extended. through and clenched upon the panel-boards. Where the socket-plates are covered by the margin l0 of the cloth, it is desirable to cut holes in the fabric-margin to correspond with the openings in the socket-plates. This may be accomplished by an operator, using a small electric cutter, as illustrated in Ratley application Ser. No. 58,427 filed January 9, 1936.

The cover and panel-board and the interposed bat may be sewed together by lines of stitching as indicated at I2 in the left-hand portion of 1. This may be accomplished by a single-head industrial sewing-machine, if desired. Preferably, it is accomplished by means of a gang sewing-machine, as indicated at P. The sewing heads are indicated at I3. Preferably the lines of stitching do not extend completely to the front and rear edges of the trim-panel. Margins may be left, and transverse lines of stitching may be used at the ends of the longitudinal lines of stitching, if desired.

If desired, the trim-panels may be wholly covered, or, if desired, a margin at the lower end of the trim-panel may be left uncovered, as indicated at i4 inFig, '7. A kick-pad may be applied in any suitable manner. Ordinarily, a strong, heavy fabric, or leather piece, is sewed to the cover-fabric at the margin indicated at I5 in Fig.' '7. This may be, and preferably is, done before the application of the covers to the panels is undertaken. For convenience, this. feature has been omitted from the drawings.

The improved process enables trim-panels to be manufactured in a continuous process in a highly economical manner and a thoroughly reliable manner. It is easily possible to produce trim-panelsl by this method to the extent of four or five hundred per hour on a single line. 'I'he number of lines may be multiplied, according to requirements.

The panel-boards Q may also be designated panel-plates. Ordinarily they are in the form of fairly stiff brous sheets, such as heavy cardboard, or composition board of suitable fibrous material. Any suitable material may be ernployed, however. If the sewing operation is to be omitted, sheet metal can be employed if desired.

The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, but the appended claims should be construed as broadly as permissible in View of the prior art.

What we regard as new and desire to secure by Letters Patent is:

i. In the manufacture of trim-panels, a method which comprises: advancing a continuous bat and a series of superposed panel-plates; rupturing the bat between the panel-plates and trimming it at the edges of the panel-plate; applying a ternplet of lesser area against the individual bat opposite each panel-plate, and trimming Vthe bats about edges of the associated templets.

2. In the manufacture of trim-panels, a method which comprises: feeding a 'continuous bat; adhesively applying panel-plates in succession to the moving bat; successively compressing the panel-plates against the moving bat and rupturing and trimming the bat about edges of the panel-plates; and applying templetsI of lesser area to the trimmed bats opposite the panel-plates and trimming the bats about edges of the templets.

3. In the manufacture of trim-panels, a method which comprises: feeding a continuous bat and a series of surmounting panel-plates; applying suction above the path of the panel-plates and rupturing the bat between panel-plates and trimming the individual bat at edges of the panelplates; inverting the panel-plates; and chamfering the edge portions of the bats on said panelplates.

4. In the manufacture of trim-panels, a method which comprises: supporting and advancing upon a conveyor a continuous bat; applying adhesive to one side of the panel-plates in succession and laying the panel-plates upon the advancing bat.

with the adhesive next to the bat; applying suction above the path of the panel-plates to draw portions of the bat upwardly through the spaces between the panel-plates andl about the lateral edges of the panel-plates; brush-trimming the upwardly drawn material about edges of the panel-plates; inverting the panel-plates; and chamfering the edge portions of the bats on said panel-plates.

5. In the manufacture of trim-panels, a method which comprises adhesively applying bats to panel-plates in succession and brush-trimming the bat-material at the edges of the panel-plates; applying templets of lesser area to the bat-covered panel-plates; and brush-trimming the individual bats about the edges of the templets to produce a beveled eifect at the edges of the bats.

6. In the manufacture of trim-panels, a method which comprises positioning and advancing on a conveyor a continuous bat; placing adhesivecoated panel-plates in succession upon the advancing bat; applying suction above the path of the panel-plates to draw the bat material upwardly about the edges of the panel-plates; placing templets above individual bats and opposed to the panel-plates; and applying suction-brushtrimming above the path of the templets.

7. In the manufacture of trim-panels, the steps which comprise: advancing assemblies, each comprising a panel-plate, a superposed bat, and a templet of lesser area superposed upon the bat; applying brush-trimming action over and about the panel-plate of the assemblies, in succession, to produce a beveled effect at the edges of the bats; advancing the series of covers; removing the templets from the bat-covered panel-plates and placing the bat-covered panel-plates upon the advancing covers with the bats adjacent to the covers; spraying with adhesive the marginal portions of the panel-plates and covers as they ad- Vance; and folding the margins of the covers over the margins of the panel-plates and effecting pasting thereon, as the assemblies advance.

8. Apparatus for the purpose set forth, comprising; bat-rupturing-and-trimming mechanism equipped with means for feeding therethrough a continuous bat and superposed panelplates, said mechanism being equipped over the path of travel of the bat and panel-plates with a suction-device; means for advancing a continuous bat and feeding said bat and panel-plates placed thereon to said mechanism; bat-trimming mechanism and a conveyor leading thereto from said first-mentioned mechanism, said bat-trimming mechanism being equipped at its upper portion with a suction-device; and templets of lesser area than individual bats associated with the panel-plates and adapted to be placed upon said individual bats and passed with the panel-plates and the interposed bats through said bat-trimming mechanism.

9. In apparatus for the purpose set forth: means for trimming the bats of bat-covered panel-plates, comprising bat-trimming mechanism having means for feeding bat-covered panelplates and superposed templets therethrough, said mechanism being equipped above the path of travel with brush-trimmers; and templets of the general configuration of the bats but of lesser area adapted to pass with the bat-covered panelplates through said bat-trimming mechanism.

Y 10. Apparatus as specified in claim 9, combined with a suction-device disposed over said brushtrimmers.

ALLISTER S. MITCHELL. HAROLD M. RATLEY. 

